Consumable selection aid for a plasma cutting system

ABSTRACT

A plasma cutting or welding system includes a power input. The power input is configured to be coupled to a plurality of multipronged input plugs. Each of the multipronged input plugs corresponds to an input voltage. The power supply also includes a user input device for selecting an operating current. The user input device is subdivided into a plurality of current ranges. Each of the current ranges includes an iconic representation of at least one multipronged input plug.

CROSS REFERENCE TO RELATED APPLICATION

This application is a Continuation patent application from U.S. patentapplication Ser. No. 13/396,190, entitled “Consumable Selection Aid fora Plasma Cutting System”, filed Feb. 14, 2012, which is hereinincorporated by reference in its entirety for all purposes.

BACKGROUND

The invention relates generally to plasma cutting systems and, moreparticularly, to a consumable selection aid for a plasma cutting system.

A plasma cutting system harnesses the energy in plasma (e.g., hightemperature ionized gas) to cut metal or other electrically conductivematerial. A plasma arc is struck between components in the plasmacutting torch and the work piece. This process creates a voltage outputbetween the cutting torch and the workpiece. Accordingly, a power supplyunit coupled to a torch and a work lead is an integral part of a plasmacutting system. The plasma cutting system may receive power from powersources with voltage and current characteristics that vary. For example,a power source that provides power to the plasma cutting system mayprovide 120 volts and 15 amps, 120 volts and 20 amps, 240 volts and 30amps, 240 volts and 50 amps, and so forth. The type of power sourcecoupled to the plasma cutting system provides limitations to a plasmacutting operation. As such, it may be difficult for an operator todetermine the appropriate current settings for a particular plasmacutting operation based on which type of power source the plasma cuttingsystem is connected to. Further, as will be appreciated, a variety ofconsumables may be used for plasma cutting. In certain configurations,the appropriate type of consumable may depend on an operating current.Unfortunately, determining the proper type of consumables to use for aparticular plasma cutting system configuration may not be easilyascertainable. Accordingly, there is a need in the field for a plasmacutting system that overcomes such deficiencies.

BRIEF DESCRIPTION

In one embodiment, a plasma cutting system having a plurality ofmultipronged input plugs configured to correspond to an input voltageand a maximum current. The plasma cutting system includes a user inputdevice for selecting an operating current. The user input device issubdivided into a plurality of current ranges. Each of the currentranges includes an iconic representation of at least one multiprongedinput plug. The plasma cutting system includes indicia representing oneof a plurality of torch tips. The indicia correlates the plurality oftorch tips with each iconic representation of the at least onemultipronged input plug.

In another embodiment, a method for controlling current provided by aplasma cutting system includes detecting a supply voltage receivedthrough a selected multipronged input plug of a plurality ofmultipronged input plugs. The method also includes receiving a userselected input from a user device to set an operating current of theplasma cutting system. The user device is subdivided into a plurality ofcurrent ranges. Each of the current ranges includes an iconicrepresentation of at least one multipronged input plug. The methodincludes limiting the operating current to a maximum current within theoperating current range if the user selected input from the user deviceis not within an operating current range of the selected multiprongedinput plug.

In another embodiment, a plasma cutting or welding system includes apower input configured to be coupled to a plurality of multiprongedinput plugs. Each of the multipronged input plugs corresponds to aninput voltage. The power supply also includes a user input device forselecting an operating current. The user input device is subdivided intoa plurality of current ranges. Each of the current ranges includes aniconic representation of at least one multipronged input plug.

DRAWINGS

These and other features, aspects, and advantages of the presentinvention will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a perspective view of an embodiment of a plasma cutting systemin accordance with aspects of the present disclosure;

FIG. 2 is a front view of an embodiment of a control panel for a plasmacutting system in accordance with aspects of the present disclosure;

FIG. 3 is a front view of another embodiment of a control panel for aplasma cutting system in accordance with aspects of the presentdisclosure;

FIG. 4 is a perspective view of an embodiment of a power connector forthe plasma cutting system of FIG. 1;

FIG. 5 is a perspective view of another embodiment of a power connectorfor the plasma cutting system of FIG. 1;

FIG. 6 is a perspective view of another embodiment of a power connectorfor the plasma cutting system of FIG. 1;

FIG. 7 is a perspective view of another embodiment of a power connectorfor the plasma cutting system of FIG. 1;

FIG. 8 is a block diagram of an embodiment of a plasma cutting system inaccordance with aspects of the present disclosure; and

FIG. 9 is a flow chart of an embodiment of a method for controllingcurrent provided by the plasma cutting system of FIG. 1 according toaspects of the present disclosure.

DETAILED DESCRIPTION

Referring now to the drawings, FIG. 1 is a perspective view illustratingan embodiment of a plasma cutting system 10. The illustrated plasmacutting system 10 includes a power supply 12 coupled to a torch 14 and awork piece clamp 16. The torch 14 includes a tip 18 having a consumableused during a plasma cutting operation. As will be appreciated, the typeof tip 18 may vary based on the operating current of the power supply12. For example, one tip 18 may be rated for operating at currents up to30 amps, while another tip 18 may be rated for operating at currents upto 40 amps. Use of the wrong tip 18 may result in poor cutting qualityor premature degradation of the tip 18.

The torch 14 is electrically coupled to the power supply 12 via a cable19. Further, the work piece clamp 16 is electrically coupled to thepower supply 12 via a cable 20. The power supply 12 is electricallycoupled to a power source (e.g., a power grid or a motor-drivengenerator) via a power cable assembly 22. The power source provides acurrent to the torch 14 for starting and generating a pilot arc, and formaintaining plasma and a cutting arc. For example, the power supply 12supplies a suitable voltage and current to create an electrical circuitfrom the power supply 12, along the cable 19 to the torch 14, across agap between the torch 14 and a work piece (e.g., as an electrical arc),through the work piece to the clamp 16, and through the cable 20 back tothe power supply 12.

The power cable assembly 22 includes a cable 24 coupled to a connector26. As explained below in relation to FIGS. 4-7, the connector 26 of thepower cable assembly 22 may include one of a variety of multiprongedplug configurations that may be used to connect the connector 26 todifferent types of power sources. As such, the power supply 12 mayinclude multiple power cable assemblies 22 with each power cableassembly 22 having a unique multipronged plug configuration. Each of themultipronged input plugs may correspond to an output voltage and/ormaximum output current of a particular power source.

The power supply 12 includes an enclosure 27 defining a generally closedvolume to support various circuits, sensor features, control features,and gas supply features (e.g., air compressor). For example, the powersupply 12 may include sensors and controls to adjust the power supply 12to account for various conditions, e.g., altitude, temperature,pressure, and so forth. The enclosure 27 may also include vents torelieve heat and/or pressure inside the power supply 12.

In the illustrated power supply 12, a control panel 28 is included onthe front of the power supply 12. The control panel 28 may includevarious control inputs, indicators, displays, electrical outputs, airoutputs, and so forth. In certain embodiments, the control panel 28 mayinclude a button, knob, switch, or touch screen configured to enableselection of a mode of operation (e.g., plasma cut, gouge, etc.), poweron/off, an output current level, gas (e.g., air) flow rate, gas (e.g.,air) pressure, gas type, a work piece type, a control type (e.g., manualor automatic feedback control), or a combination thereof. The controlpanel 28 may also include various indicators to provide feedback to theuser. For example, the indicators may include one or more light emittingdiodes (LED) and/or liquid crystal displays (LCD) to display on/offstatus, current level, voltage level, gas (e.g., air) pressure, gas(e.g., air) flow, environmental conditions (e.g., altitude, temperature,pressure, etc.), or any other parameter. Additionally, the indicatorsmay include an LED or LCD that displays a trouble or warning indicatorif there is a problem with the power supply 12.

Embodiments of the control panel 28 may include any number inputs andoutputs, such as welding methods, air compressor settings, oil pressure,oil temperature, and system power. Further, the user inputs andindicators may be electrically coupled to control circuitry and enable auser to set and monitor various parameters of the power supply 12. Forexample, the indicators may display environmental conditions (e.g.,altitude, temperature, pressure, etc.) that prompt a user to manuallyadjust the current, voltage, gas flow rate, gas pressure, or otheroperational parameters, or a combination thereof.

As described in detail below, the control panel 28 may include acorrelation between graphical representations of multipronged inputplugs, and an operating current range and/or a tip 18. As such, anoperator may easily determine the appropriate operating current and/ortip 18 based a graphic on the surface of the power supply 12 that lookslike the end of the connector 26 (e.g., multipronged plug) that connectsthe power supply 12 to the power source.

FIG. 2 is a front view of an embodiment of the control panel 28 for theplasma cutting system 10. The control panel 28 includes a user inputdevice 30 (e.g., knob, dial, touch screen, etc.) for adjusting theoutput current setting (e.g., operating current) of the power supply 12.The control panel 28 also includes indicia 32 to aid an operator indetermining an appropriate tip 18 and output current setting based onthe appearance of the end of the connector 26 that connects the powersupply 12 to the power source. Further, the control panel 28 includesindicators 34 that provide feedback to the operator about conditions ofthe power supply 12, plasma cutting system 10, and/or environmentalfactors.

The user input device 30 may be used to adjust the output currentsetting of the power supply 12 within a variety of current ranges. Forexample, the output current settings may be divided into a first range36, a second range 38, and a third range 40. As will be appreciated, thefirst range 36, the second range 38, and the third range 40 may includeoverlapping positions. In certain embodiments, the first range 36 mayinclude current settings between 15 and 20 amps, the second range 38 mayinclude current settings between 15 and 27 amps, and the third range 40may include current settings between 15 and 40 amps. However, as may beappreciated, the first range 36, the second range 38, and the thirdrange 40 may include current settings that vary between any suitablevalues. Various graphical indicators or indicia may be used on thecontrol panel 28 to assist an operator in determining which range orranges the user input device 30 is set within. For example, the controlpanel 28 may include color coded regions, divider lines, text, etc.

Further, a graphical or iconic representation of one or moremultipronged input plugs (e.g., based on National ElectricalManufacturers Association (NEMA) standards) may be included within theranges 36, 38, and 40 to show which multipronged input plugs correspondto a particular one of the ranges 36, 38, and 40. For example, arepresentation of a first multipronged input plug configuration 42(e.g., NEMA 5-15) is illustrated as corresponding to the first range 36.Further, a representation of a second multipronged input plugconfiguration 44 (e.g., NEMA 5-20) is illustrated as corresponding tothe second range 38. In addition, a representation of a thirdmultipronged input plug configuration 46 (e.g., NEMA 5-50) and arepresentation of a fourth multipronged input plug configuration 48(e.g., NEMA L6-30) are both illustrated as corresponding to the thirdrange 40. As will be appreciated, any type of representation may be usedto represent a particular multipronged input plug configuration. Forexample, the representation may be graphical, iconic, symbolic, text,NEMA names, pictures, videos, color coding, letter coding, etc. As willbe appreciated, the representations of the multipronged input plugconfiguration provide a visual representation to a user of the plasmacutting system 10 so that the user can determine a correct operatingrange 36, 38, or 40 merely by comparing the representation of themultipronged input plug configuration to the plug configuration of theconnector 26 (e.g., or adaptor) that connects to the power source.

The indicia 32 may include a table like configuration as illustrated. Assuch, different types of tips 18 may be correlated with one or more ofthe ranges 36, 38, and 40 and/or the representations of the multiprongedinput plug configurations 42, 44, 46, and 48. For example, a first tip50 (e.g., a tip rated for operation up to 30 amps) may correspond to theranges 36 and 38 and to the representation of the multipronged inputplug configurations 42 and 44. Further, a second tip 52 (e.g., a tiprated for operation up to 40 amps) may correspond to the range 40 and tothe representation of the multipronged input plug configurations 46 and48. In other embodiments, any type of tip may correspond to a suitableoperating current range and/or representation of a multipronged inputplug configuration. The indicia 32 that correlates the tips 18 with theranges 36, 38, and 40 and/or the representations of the multiprongedinput plug configurations 42, 44, 46, and 48 may be any suitableindicia. For example, the indicia 32 may be graphical, iconic, symbolic,text, pictures, videos, color coding, letter coding, etc. As will beappreciated, the indicia 32 provide visual indications to a user of theplasma cutting system 10 so that the user can determine a correct tip 18merely by comparing the indicia 32 to a correctly set operating range36, 38, or 40, and/or by comparing the indicia 32 to a representation ofthe multipronged input plug configuration that matches the plugconfiguration of the connector 26 (e.g., or adaptor) that connects tothe power source. Thus, a correct tip 18 may be determined resulting inbetter plasma cutting and/or extended longevity of the tip 18.

As illustrated, the control panel 28 may also include the indicators 34.For example, the control panel 28 may include a power indicator 54, apressure indicator 56, a cup indicator 58, and a temperature indicator60. The power indicator 54 provides an indication that the power supply12 is powered on. In certain embodiments, a flashing power indicator 54may indicate a problem with the power being provided to the power supply12. The pressure indicator 56 relates to pressure in the plasma cuttingsystem 10, the cup indicator 58 relates to the status of a torch cup,and the temperature indicator 60 relates to the operating temperature ofthe plasma cutting system 10. Generally when the power indicator 54 ison, the pressure indicator 56, the cup indicator 58, and the temperatureindicator 60 will be off, indicating normal system operation. If any ofthe indicators 56, 58, and 60 are on, or flashing, there may be aproblem in the plasma cutting system 10.

FIG. 3 is a front view of another embodiment of the control panel 28 forthe plasma cutting system 10. In this embodiment, only one tip 18 isused for all current ranges of plasma cutting. Therefore, the indicia 32does not include representations illustrating a correlation between atype of torch tip 18, and the ranges 36, 38, and 40 and/or themultipronged input plug configurations 42, 44, and 46. As illustrated, arepresentation of the first multipronged input plug configuration 42 isillustrated as corresponding to the first range 36. Further, arepresentation of the second multipronged input plug configuration 44 isillustrated as corresponding to the second range 38. In addition, arepresentation of the third multipronged input plug configuration 46 isillustrated as corresponding to the third range 40. As such, therepresentations of the multipronged input plug configuration provide avisual representation to a user of the plasma cutting system 10 so thatthe user can determine a correct operating range 36, 38, or 40 merely bycomparing the representation of the multipronged input plugconfiguration to the plug configuration of the connector 26 (e.g., oradaptor) that connects to the power source.

FIGS. 4-7 illustrate various embodiments of multipronged input plugconfigurations. These embodiments are examples of multipronged inputplug configurations. It should be noted that any suitable plugconfiguration may be used with the plasma cutting system 10.Specifically, FIG. 4 is a perspective view of an embodiment the firstmultipronged input plug configuration 42 of the power connector 26 forthe plasma cutting system 10 of FIG. 1. The plug configuration 42includes two rectangular and generally vertical prongs 62 that aresubstantially the same size. The plug configuration 42 also includes agenerally circular prong 64. As will be appreciated, the plugconfiguration 42 is generally used for connecting to a power sourcerated to provide 120 volts AC and 15 amps.

FIG. 5 is a perspective view of an embodiment the second multiprongedinput plug configuration 44 of the power connector 26 for the plasmacutting system 10 of FIG. 1. The plug configuration 44 includes a firstrectangular prong 66 that is oriented in a generally vertical position,and a second rectangular prong 68 that is oriented in a generallyhorizontal position. The plug configuration 44 also includes a generallycircular prong 70. As will be appreciated, the plug configuration 44 isgenerally used for connecting to a power source rated to provide 120volts AC and 20 amps.

FIG. 6 is a perspective view of an embodiment the third multiprongedinput plug configuration 46 of the power connector 26 for the plasmacutting system 10 of FIG. 1. The plug configuration 46 includes a firstrectangular prong 72 and a second rectangular prong 74, both of theprongs 72 and 74 are oriented in a generally horizontal position,however the prong 72 extends a greater vertical distance than the prong74. The plug configuration 46 also includes a generally circular prong76. As will be appreciated, the plug configuration 46 is generally usedfor connecting to a power source rated to provide 240 volts AC and 50amps.

FIG. 7 is a perspective view of an embodiment the fourth multiprongedinput plug configuration 48 of the power connector 26 for the plasmacutting system 10 of FIG. 1. The plug configuration 48 includessemi-circular shaped prongs 78 that are substantially the same size. Theplug configuration 48 also includes a keyed semi-circular shaped prong80. As will be appreciated, the plug configuration 48 is generally usedfor connecting to a power source rated to provide 240 volts AC and 30amps.

FIG. 8 is a block diagram of an embodiment of the plasma cutting system10. As illustrated, an AC power source 82 may provide power to the powersupply 12. Specifically, the power cable assembly 22 may couple thepower supply 12 to an adaptor 84. The adaptor 84 is coupled between thepower cable assembly 22 and the AC power source 82. In such aconfiguration, the power cable assembly 22 may use a single connector 26(having a single plug configuration) to connect to multiple types of ACpower sources 82. For example, the connector 26 may have the plugconfiguration 42 as illustrated in FIG. 4. The adaptor 84 may have areceptacle to match the plug configuration 42 on one end, and on theother end the adaptor 84 may have any other plug configuration (e.g.,plug configuration 44, 46, or 48). Such an adaptor may be an adaptor asdescribed in U.S. application Ser. No. 12/183,516, entitled “POWER CORDSYSTEM FOR WELDING-TYPE DEVICES,” filed Jul. 31, 2008, which is herebyincorporated by reference in its entirety.

FIG. 9 is a flow chart of an embodiment of a method 86 for controllingcurrent provided by the plasma cutting system 10 of FIG. 1. At block 88,the power supply 12 detects a supply voltage received through a selectedmultipronged input plug of the multipronged input plug configurations42, 44, 46, and 48. Next, at block 90, the power supply 12 receives auser selected input from the user input device 30 to set the operatingcurrent of the plasma cutting system 10. As previously described, theuser input device 30 is subdivided into the ranges 36, 38, and 40. Eachof the ranges 36, 38, and 40 is correlated to an iconic representationof at least one of the multipronged input plug configurations 42, 44,46, and 48. Further, each of the ranges 36, 38, and 40 may be correlatedto one of the torch tips 50 and 52. In certain embodiments, a user mayselect one of the torch tips 50 and 52 based on the selectedmultipronged input plug configuration 42, 44, 46, or 48, per block 92.As will be appreciated, the user may select the torch tip 50 or 52 basedon an iconic representation of the multipronged input plug configurationand/or other indicia. At block 94, control circuitry of the power supply12 may limit the operating current of the plasma cutting system 10 to amaximum current within the applicable operating current range if theuser selected input from the user input device 30 is not within anapplicable operating current range of the selected multipronged inputplug. In certain configurations, if a user sets the user selected inputfrom the user input device 30 higher than the applicable operatingcurrent range of the selected multipronged input plug, the power supply12 may attempt to use greater current than available and cause a circuitbreaker to trip. Using such a method, the user can determine a correctoperating range 36, 38, or 40 and/or tip 18 merely by comparing therepresentation of the multipronged input plug configuration to the plugconfiguration of the connector 26 (e.g., or adaptor) that connects tothe power source. As will be appreciated, while the embodimentsdescribed herein have been discussed as being within the plasma cuttingsystem 10, the embodiments may also be incorporated into weldingsystems, induction heating systems, generator systems, and so forth.

While only certain features of the invention have been illustrated anddescribed herein, many modifications and changes will occur to thoseskilled in the art. It is, therefore, to be understood that the appendedclaims are intended to cover all such modifications and changes as fallwithin the true spirit of the invention.

The invention claimed is:
 1. A plasma cutting or welding systemcomprising: a plurality of multipronged input plugs, wherein each of themultipronged input plugs is configured to correspond to a differentinput voltage or a different maximum current of a power source; acontrol panel comprising a user input device for selecting an operatingcurrent, the user input device being subdivided into a plurality ofcurrent ranges, wherein each of the current ranges comprises an iconicrepresentation of at least one multipronged input plug; and controlcircuitry configured to limit an operating current of the plasma cuttingor welding system based at least in part on the selected operatingcurrent and a voltage received through a selected multipronged inputplug.
 2. The system of claim 1, wherein the control panel comprisesfirst indicia representing one of a plurality of torch tips, wherein theindicia correlates at least one of the plurality of torch tips with eachiconic representation of the at least one multipronged input plug. 3.The system of claim 2, wherein the control panel comprises secondindicia that correlates each of the multipronged input plugs with atleast one of the plurality of current ranges.
 4. The system of claim 2,wherein each of the plurality of torch tips is configured to operatewithin at least one of the plurality of current ranges.
 5. The system ofclaim 1, wherein each of the multipronged input plugs comprises anadaptor having a first end configured to be coupled to a power sourceand a second end configured to direct power to the plasma cutting orwelding system.
 6. A method comprising: detecting a supply voltagereceived through a selected multipronged input plug of a plurality ofmultipronged input plugs, wherein each of the multipronged input plugscorresponds to a different input voltage of a power source; receiving auser selected input from a user device disposed on a control panel of aplasma cutting or welding system, the user device being subdivided intoa plurality of current ranges, wherein each of the current rangescomprises an iconic representation of at least one multipronged inputplug; and limiting an operating current of the plasma cutting or weldingsystem based at least in part on the user selected input and a voltagereceived through the selected multipronged input plug.
 7. The method ofclaim 6, wherein the iconic representation of the at least onemultipronged input plug corresponds to one of a plurality of torch tips.8. The method of claim 7, comprising selecting a torch tip from theplurality of torch tips based on the selected multipronged input plug.9. The method of claim 7, comprising indicia of the plurality of torchtips that correlates the plurality of torch tips with an iconicrepresentation of the at least one multipronged input plug.
 10. Themethod of claim 9, comprising selecting a torch tip from the pluralityof torch tips based on the indicia.
 11. The method of claim 6, whereinthe iconic representation indicates that the at least one multiprongedinput plug is configured to operate within the respective current range.12. A plasma cutting or welding system comprising: a power inputconfigured to be coupled to a plurality of multipronged input plugs,wherein each of the multipronged input plugs corresponds to a differentinput voltage of a power source; a control panel comprising a user inputdevice for selecting an operating current, the user input device beingsubdivided into a plurality of current ranges, wherein each of thecurrent ranges comprises an iconic representation of at least onemultipronged input plug; and control circuitry configured to limit anoperating current of the plasma cutting or welding system based at leastin part on the selected operating current and a voltage received througha selected multipronged input plug.
 13. The system of claim 12,comprising the plurality of multipronged input plugs, wherein each ofthe multipronged input plugs comprises an adaptor having a first endconfigured to be coupled to a power source and a second end configuredto direct power to the power input.
 14. The system of claim 12, whereinthe iconic representation of the at least one multipronged input plugcorresponds to one of a plurality of torch tips.
 15. The system of claim14, wherein each of the plurality of torch tips is configured to operatewithin at least one of the plurality of current ranges.
 16. The systemof claim 14, comprising indicia of the plurality of torch tips thatcorrelates the plurality of torch tips with an iconic representation ofthe at least one multipronged input plug.
 17. The system of claim 12,comprising a plasma cutting torch configured to use the operatingcurrent for plasma cutting.
 18. The system of claim 12, comprisingindicia that correlates each of the multipronged input plugs to at leastone of the plurality of current ranges.
 19. The system of claim 18,wherein the indicia correlates at least one of the multipronged inputplugs to at least two current ranges, the at least two current rangescomprising overlapping color regions.
 20. The system of claim 18,wherein the indicia comprises at least one of a graphic, an icon, asymbol, a picture, a video, a color, or text for each of themultipronged input plugs.